LM6000 PC GEK 105059

GE Industrial AeroDerivative Gas Turbines Volume II

WP 4014 00
7WP 4014 00
WORK PACKAGE

TECHNICAL PROCEDURES
GAS TURBINE WATER-WASH
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS

LIST OF EFFECTIVE WP PAGES

Total Number of Pages in this WP is 8

Page Change Page Change Page Change

No. No. No. No. No. No.
1-7 ...... 7
8 Blank ...... 7

Alphabetical Index

Subject Page

Crank/Soak Cleaning .................................................................................................................. 4

On-Line Cleaning........................................................................................................................ 7
Water and Detergent Requirements............................................................................................. 3
Water-Wash Description ............................................................................................................. 3

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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 4014 00

1. Introduction.

This work package contains instructions for performing water-wash procedures on the LM6000
gas turbine.

2. Reference Material.

Title Number
Operation & Maintenance Manual GEK 105059
Compressor Cleaning Water Purity Specification for GE Air-
craft Derivative Gas Turbines in Industrial Applications Appendix A4
Liquid Detergent for Compressor Cleaning for GE Aircraft
Derivative Gas Turbines in Industrial Applications Appendix A5
System Descriptions Chapter 5
Engine Operation Chapter 8
Borescope Inspection WP 4015 00

3. Support Equipment.

None required.

4. Consumable Material.

Nomenclature Specification
ARDROX 6322 (solvent base) Local Purchase
CleanBladeTM GTC1000 Local Purchase
Conntect (water base) Local Purchase
Isopropyl Alcohol Fed Spec TT-I-735
Monopropylene Glycol AMS 1424
PROTOKLENZ-GT-SC Local Purchase
RMC Turbine/Engine Cleaner (solvent Local Purchase
base)
Rochem FYREWASH (solvent base) Local Purchase
Techniclean GT (water base) Local Purchase
Turbotect 950 (water base) Local Purchase
Turbo-K Local Purchase
Zok 27 and Zok 27LA (water base) Local Purchase

5. Expendable Material.

None required.

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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 4014 00

6. Water-Wash Description.

The following basic water-wash procedures may be applied:

A. Crank/Soak Cleaning: Applied while motoring the high pressure (HP) rotor at greater than
2000 RPM and low pressure (LP) rotor at greater than 200 RPM. Used for performing a thor-
ough cleaning of engine. Crank-soak washing removes oily or tarry deposits which bind dirt
to blade. The frequency of wash must be tailored to type of atmospheric contaminants, tem-
perature, operational frequency/profile, gas turbine health and site economics. In the absence
of this information a prudent strategy would be to crank-soak wash every 2 weeks.

B. On-line Cleaning: Applied while engine is running. Requires special on-line cleaning mani-
fold. It is used primarily to maintain gas turbine performance between crank-soak washes but
rarely is able to make a significant improvement in performance.

7. Water and Detergent Requirements.

A. Water quality and liquid detergent for crank/soak compressor cleaning must meet require-
ments specified in Appendix A4 and Appendix A5,Volume I of this manual.

B. The liquid detergents listed below may be used for performing water-wash procedures. Fol-
low liquid detergent manufacturer's instructions for recommended detergent/water dilution
ratios. Ensure that detergents used, including those listed, meet requirements specified by
packager.

ARDROX 6322 (solvent base)

CleanBladeTM GTC1000

Conntect (water base)

PROTOKLENZ-GT-SC

RMC Turbine/Engine Cleaner (solvent base)

Rochem FYREWASH (solvent base)

Techniclean GT (water base)

Turbotect 950 (water base)

Turbo-K

Zok 27 and Zok 27LA (water base)

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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 4014 00

C. In freezing weather, mix one of the antifreeze agents listed below with cleaning solution.
Refer to Appendix A5 for recommended solution mixtures and additional information.

Isopropyl alcohol

Monopropylene Glycol

8. Crank/Soak Cleaning.

A. Before initiating crank/soak cleaning sequence, comply with the following requirements:

WARNING
The enclosure area shall be ventilated. The engine shall be shut
down and cooled prior to crank/soak cleaning. All drains shall
be open.

Concentrated B & B 3100 solvent, acetone, and isopropyl alco-

hol are flammable and toxic to skin, eyes, and respiratory
tract. Skin, eye, and respiratory protection is required. Avoid
repeated or prolonged contact. Use with good ventilation.

CAUTION
Be certain that checklists have been established for packager-
furnished equipment. Consult the packagers manual for mandatory
pre-start procedures, especially making sure that the packager-
furnished lube supply sub-system is activated and operational prior
to any motoring sequence. Failure to comply may result in part
damage.

(1) If crank/soak cleaning is not preceded by an extended shutdown period, perform a nor-
mal shutdown (including 5 minutes at core idle for cooling). Refer to Chapter 8,
Volume I of this manual for engine shutdown procedures.

(2) Allow gas turbine to cool so that outside surfaces are less than 200F (93C).

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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 4014 00

WARNING

If natural gas is used to drive the starter, additional safety precau-

tions are required. These include safety measures for combustible
gases and venting of starter exhaust to a safe location.

NOTE
While motoring the engine with the starter, ensure that a minimum
lube pressure of 6 psig (41 kPa) is maintained.

(3) To expedite cooling, motoring starter is permissible. Dry motoring procedures are con-
tained in to Chapter 8, Volume I of this manual. Limit starter duty cycles to those defined
in Chapter 5, Volume I.

B. Perform crank/soak cleaning cycle as follows:

(1) Motor HP rotor to 2,000 rpm and allow speed to stabilize. Low pressure (LP) rotor speed
should be 200-300 rpm. Allow LP rotor speed to stabilize before initiating water flow.

CAUTION
In below freezing conditions, antifreeze agents shall be added to the
water. The use of non-isopropyl alcohol, ethylene glycol, and addi-
tives containing chlorine, sodium, or potassium are not permitted
since they may attack titanium and other metals in the engine.

NOTE

Total solids in the wash and rinse waters shall be no more than 100
ppm. The ph factor shall be between 6.5 and 8.5 at 77F (25C).
Potable water will normally meet these requirements. Water-wash
solution should be at room temperature and a flow rate of approxi-
mately 20 gpm (76 liters/minute).

Residual waste following water-wash with solvent should be dis-

posed of in accordance with local environmental regulations for
the specific geographic location. Users should contact the solvent
supplier for details relative to the solvent used.

Packager-supplied control system will open the VIGVs and will

close the VBVs.

(2) Inject 20 gallons (76 liters) of water-wash solution through crank/soak water-wash man-
ifold while motoring HP rotor at approximately 2,000 rpm and LP rotor at 200-300 rpm.

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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 4014 00

CAUTION

Packager-supplied control system shall automatically close the water

wash injection valve if LP rotor speed drops below 200 RPM or HP
rotor speed drops below 2000 RPM. Water injection at lower speeds
may result in water entering LP or HP compressors rotors, which
may result in major engine damage.

(3) After completion of wash solution injection, close the variable inlet guide vanes
(VIGVs) and maintain variable bypass valves (VBVs) in closed position. Allow rotors to
coast to a stop and the solution to soak for 10 minutes. For systems with driven equip-
ment having large rotational inertia, it may not be practical to coast to a stop and the soak
will be a rolling soak.

NOTE
For systems with driven equipment having large rotational inertia,
it may not be practical to allow the rotors to coast to a stop. The
soak will be a rolling soak.

During wash cycle, approximately 10 percent of the water and

cleaning solution will leak through the engine casings and open-
ings to the exterior of the engine.

C. Complete two rinse cycles as follows:

(1) Open inlet drain, bleed air collector drain, exhaust collector drains, and module drains to
remove any wash solution and rinse water after washing is complete.

(2) Use a minimum of 25 gallons (95 liters) of 160 to 180F (71 to 82C) water, while
motoring HP rotor at approximately 2,000 rpm and LP rotor at 200-300 rpm.

NOTE
Rinsing performed using unheated water will require more water to
achieve the same rinsing effectiveness as heated water.

(3) After rinsing, shut off water supply.

(4) Regulate pneumatic starter air supply for normal operation.

(5) Open low pressure compressor (LPC) variable bleed valves.

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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 4014 00

D. As an option, operator may inspect gas turbine to determine if cleaning process was adequate
as follows:

(1) After completion of the rinse cycles, allow rotors to coast to a complete stop.

(2) Borescope inspect LPC and high pressure compressor (HPC) rotors per WP 4015 00,
Volume II of this manual, paying particular attention to stator/blade airfoils.

(3) If excessive contaminants are still present, rewash as required.

E. Make a normal engine start and allow engine to run at synchronous idle for 2-3 minutes to
dry engine.

9. On-Line Cleaning.

CAUTION

Antifreeze mixtures for on-line water-wash and rinse should be used

when ambient temperatures are 50F (10C) or less. Formation of
ice may result in major engine damage.

A. Prepare on-line wash solution with water and detergent per packager's manual.

B. Limit total amount of on-line wash solution and rinse water to 100 gal/day (378.5 liters/day)
maximum.

C. Refer to packager's manual for specific amount of wash solution and frequency of on-line
wash.

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